EP1183762B1 - Culot de bougie d'allumage comportant une electrode de masse bimetallique, bougie d'allumage equipee dudit culot et procede de fabrication associe - Google Patents

Culot de bougie d'allumage comportant une electrode de masse bimetallique, bougie d'allumage equipee dudit culot et procede de fabrication associe Download PDF

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Publication number
EP1183762B1
EP1183762B1 EP00941440A EP00941440A EP1183762B1 EP 1183762 B1 EP1183762 B1 EP 1183762B1 EP 00941440 A EP00941440 A EP 00941440A EP 00941440 A EP00941440 A EP 00941440A EP 1183762 B1 EP1183762 B1 EP 1183762B1
Authority
EP
European Patent Office
Prior art keywords
spark plug
shell
ground electrode
recess
metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP00941440A
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German (de)
English (en)
Other versions
EP1183762A1 (fr
Inventor
Jeffery T. Boehler
Gary B. Zulauf
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Honeywell International Inc
Original Assignee
AlliedSignal Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by AlliedSignal Inc filed Critical AlliedSignal Inc
Publication of EP1183762A1 publication Critical patent/EP1183762A1/fr
Application granted granted Critical
Publication of EP1183762B1 publication Critical patent/EP1183762B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01T—SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
    • H01T13/00—Sparking plugs
    • H01T13/20—Sparking plugs characterised by features of the electrodes or insulation
    • H01T13/32—Sparking plugs characterised by features of the electrodes or insulation characterised by features of the earthed electrode
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01T—SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
    • H01T21/00—Apparatus or processes specially adapted for the manufacture or maintenance of spark gaps or sparking plugs
    • H01T21/02—Apparatus or processes specially adapted for the manufacture or maintenance of spark gaps or sparking plugs of sparking plugs

Definitions

  • the present invention relates to spark plugs for internal combustion engines, and to a method of making such spark plugs. More particularly, the present invention relates to a spark plug having a bimetallic ground electrode, and to a method of making such a spark plug.
  • Spark plugs are widely used to ignite fuel in internal combustion engines. Spark plug electrodes are subject to intense heat, and to a highly corrosive environment, generated by the exploding air/fuel mixture. To improve durability and erosion resistance, spark plug electrodes must be able to withstand the high temperature and corrosive environment resulting from the chemical reaction products between air, fuel, fuel additives, and recirculated exhaust gases within a combustion chamber.
  • a bimetallic ground electrode includes a central core material, usually including copper, and a surrounding cladding material which is different from the central core material.
  • This central core material is more thermally conductive than the surrounding cladding, and therefore conducts heat away from the firing tip of the ground electrode better than the previous designs.
  • a cooler ground electrode is preferable because it does not erode as quickly as a hotter electrode. As a result, a cooler electrode contributes to a longer useful spark plug life.
  • U.S. patent 5,530,313 to Chiu discloses a method of welding a copper cored ground electrode to a metal spark plug shell, in which a metal sheath of the ground electrode surrounds a copper core, and in which the metal sheath penetrates deeper into the metal shell than the copper core to provide an anchor therefor.
  • An electrode 116 which has a metal sheath 119 extending beyond a central copper core 117 is shown in Figure 3 of the present specification.
  • a prior art ground electrode such as the electrode 116 shown in Figure 3
  • the area of contact between the electrode sheath 119 and the shell base is still somewhat limited.
  • EP-A-0859437 discloses a spark plug with a circular ground electrode which, on mounting, is fixed in a circular recess made in a metal spark plug shell.
  • the recess is for the purpose of centring the circular ground electrode on the same axis as the center electrode.
  • the present invention provides an improved spark plug for use with internal combustion engines.
  • improved bonding is obtained between a bimetallic ground electrode and a spark plug shell having a recess formed therein to receive a tip end of the ground electrode.
  • a spark plug according to the invention includes a metal shell, an insulator coaxially disposed within the metal shell, and a center electrode coaxially disposed in the insulator.
  • the metal shell has a base portion, and the base portion has a lower surface with a recess formed therein.
  • the recess in the lower surface of the metal shell is preferred to be a substantially continuous annular grove extending around the lower surface.
  • a bimetallic ground electrode is affixed to the lower surface of the spark plug shell base, at the recess thereof.
  • the ground electrode has a central core formed of a first thermally conductive metal, which preferably includes copper.
  • the ground electrode also has an external sheath surrounding the core, the sheath being made of nickel.
  • the present invention also encompasses a method of making a spark plug, including a first step of providing a metal shell with a cylindrical base portion, in which the base portion includes a lower surface with a recess formed therein.
  • the method also includes a step of providing a ground electrode having a central core formed from a thermally conductive metal, and an external sheath surrounding the case, the metal from which the core is made having higher thermal conductivity than the surrounding sheath.
  • the method also includes a further step of placing a tip end of the ground electrode adjacent the lower surface of the shell and aligned with the recess thereof, such that part of the tip end of the ground electrode enters into the recess. Another step in the method involves welding the ground electrode to the spark plug shell.
  • the spark plug 10 includes a metal casing or shell 12 having an externally threaded cylindrical base 14 for threadable engagement in a cylinder head (not shown).
  • a bimetallic ground electrode 16 is welded on to the lower surface 15 of the threaded base 14.
  • the spark plug 10 further includes a ceramic insulator 18 disposed concentrically within the shell 12, and a center electrode 20 disposed concentrically within the insulator 18.
  • the center electrode 20 is preferred to include a central core 21 made of a thermally conductive material such as copper or a copper alloy.
  • An electrically conductive insert or rod 11 fits into the upper end of the insulator 18 opposite the center electrode 20, and a refractory glass-carbon composite material is disposed between the lower end of the insert 11 and the center electrode, to provide an internal resistor 13 within the spark plug 10.
  • spark plug shell 12 shown as a component of the spark plug 10 is physically different from the shell 12 shown in Figure 2, these differences go primarily to different sealing surfaces.
  • the respective spark plug shells 12 of Figures 1 and 2 are included as illustrative examples of the invention, and are simply configured for alignment thereof in different applications, as is well known in the art.
  • the different physical configurations of the spark plug shells 12 do not substantially affect the shell for purposes of the present invention. Accordingly, both of these shells will be referred to generically and interchangeably, throughout the present specification, with the same reference number 12.
  • Other modified configurations of spark plug shells are also compatible with the present invention.
  • the terms “upper”, “lower” and similar relative terms are used to refer to the orientation of the spark plug shell 12 and other parts of the spark plug 10 in the orientation shown in Figures 1-2. It will be understood that the spark plug may be inverted or placed on its side, and that in some applications, spark plugs are installed in a different orientation from that shown in Figures 1-2. Accordingly, these terms are not intended to be absolute, but rather, to relate to, and to illustrate specific examples of the invention.
  • the ground electrode 16 includes a central core 17 ( Figure 2, 4) formed from a first metal which is thermally conductive.
  • the ground electrode 16 further includes an exterior sheath 19 surrounding the central core.
  • the material of the central core 17 is preferred to contain copper, silver, an alloy containing copper and/or silver, or another metal having higher thermal conductivity than that of the surrounding sheath 19.
  • the sheath 19 is preferred to be made of a nickel alloy. Suitable nickel alloys for the sheath are well known in the art.
  • ground electrode 16 for use in accordance with the present invention is one made in accordance with the teachings of co-pending patent application serial number 09/228,450, filed January 11, 1999.
  • other bimetallic ground electrodes having central thermally conductive cores therein and consistent with the present specification, may be used in the practice of the present invention.
  • ground electrode 16 in accordance with the invention might be 1.2 mm in diameter, and out of that, 0.6 mm could be the central core 17, with an outer cladding 19 of 0.3 mm on each side of the core.
  • ground electrode 16 is shown in Figures 2, 4 and 5 oriented in a substantially straight or linear configuration thereof, and is attached to the shell 12 in a linear configuration during the manufacturing process, those in the art will realize and understand that after attachment of the ground electrode 16 to the spark plug shell, it will be bent substantially in a right angle configuration, and will then have a configuration substantially as shown in Figure 1.
  • the spark plug 10 according to the invention may also include first and/or second wear-resistant electrode tips 22, 24 which are attached to the ground and/or to the center electrodes 16, 20 respectively.
  • each of the wear-resistant electrode tips 22, 24 is preferably formed from a material which includes a noble metal such as platinum, iridium, or alloys thereof.
  • a noble metal such as platinum, iridium, or alloys thereof.
  • One alloy suitable for electrode tips is 85-95% platinum and 5-15 % nickel. Examples of suitable wear-resistant spark plug tips may be found in U.S. patent numbers 4,810,220 and 5,456,624. In the event that only a single wear-resistant electrode tip is used in the practice of the present invention, it is preferred to be a fine wire tip attached to the center electrode 20 as taught by the disclosure of U.S. patent number 5,456,624.
  • the spark plug shell 12 is a substantially cylindrical sleeve having a hollow bore 32 formed therethrough.
  • the spark plug shell 12 includes a cylindrical base portion 14 which generally has threads formed on the exterior surface thereof.
  • the spark plug shell 12 includes a sealing surface 34 for contacting a cylinder head (not shown), and also includes a generally hexagonal boss 36 thereon, above the sealing surface, to allow for grasping and turning thereof using a suitable tool, such as a conventional spark plug socket.
  • the lower surface 15 thereof rather than being entirely flat, has a recess 23 formed therein. This recess 23 is located approximately midway between the outer edge 30 of the lower surface 15 and the central bore 32 of the spark plug shell. The recess 23 is provided to aid in alignment of the tip end 27 of the ground electrode 16 with the shell 12.
  • the provision of the recess 23 also provides greater surface contact area between the sheath 19 and the shell 12 than would be possible without the recess 23, to promote improved adhesion therebetween when the ground electrode 16 is welded on to the shell 12.
  • a superior bonding zone 26 between the ground electrode 16 and the shell base 14 is suggested by the dashed line in Figure 5, after these two components have been joined together.
  • the recess 23 is provided in the form of an annular groove 25 extending substantially continuously and concentrically around the lower surface 15 of the shell 12.
  • the provision of the annular groove 25 further acts to minimize welding flash projections moving into the shell bore 32, or on to the threaded exterior surface of the shell base 14.
  • the tip end 27 of the ground electrode includes a reduced diameter portion 28, which substantially forms a point thereon. This reduced diameter portion 28 fits into the recess 23 of the shell 12 and helps to promote alignment of the ground electrode 16 therewith.
  • a first step involves providing a metal spark plug shell 12 with a cylindrical base portion 14, in which the base portion includes a lower surface 15 with a recess 23 formed therein.
  • the method also includes a step of providing a ground electrode 16 having a central core 17 formed from a thermally conductive material.
  • the thermally conductive material used is a first metal as previously discussed herein, and may include copper.
  • the method also includes a further step of placing a tip end 27 of the ground electrode 16 adjacent the lower surface 15 of the shell 12 and aligned with the recess 23 thereof ( Figure 4), such that part of the tip end 27 of the ground electrode enters into the recess.
  • Another step in the method involves welding the ground electrode 16 on to the spark plug shell 12.
  • the welding may be accomplished by electrical resistance welding, by laser welding, or by other known welding process.
  • a complete spark plug 10 may then be formed, following the known process for the remaining steps, using the shell 12 as a component thereof.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Spark Plugs (AREA)

Claims (17)

  1. Bougie d'allumage (10), comprenant un culot en métal (12) ayant une partie de base (14) dans laquelle est formé un orifice central, un isolant (18) disposé coaxialement à l'intérieur de l'orifice central du culot métallique et une électrode centrale (20) disposée coaxialement dans l'isolant, et
    une électrode de masse (16) fixée à une surface inférieure (15) de la partie de base, l'électrode de masse comprenant une âme centrale (17), formée d'un premier métal thermoconducteur, et une gaine externe (19) entourant l'âme, la gaine étant formée d'un deuxième métal comprenant du nickel, caractérisée en ce que la surface inférieure de la partie de base présente un évidement (23) et en ce que l'électrode de masse est fixée à la surface inférieure de la partie de base dans son évidement.
  2. Bougie d'allumage selon la revendication 1, dans laquelle la surface inférieure du culot métallique a un bord externe et dans laquelle l'évidement est situé entre le bord externe de la surface inférieure et l'orifice central du culot métallique.
  3. Bougie d'allumage selon la revendication 2, dans laquelle l'évidement se présente sous la forme d'une rainure annulaire s'étendant autour de la surface inférieure.
  4. Bougie d'allumage selon la revendication 3, dans laquelle la rainure annulaire s'étend de manière sensiblement continue autour de la surface inférieure.
  5. Bougie d'allumage selon la revendication 1, dans laquelle le premier métal est choisi dans le groupe constitué du cuivre, de l'argent, des alliages de cuivre, des alliages d'argent et de leurs mélanges.
  6. Bougie d'allumage selon la revendication 1, comprenant en outre au moins une pointe d'électrode résistant à l'usure (22, 24) fixée à l'électrode centrale ou à l'électrode de masse.
  7. Bougie d'allumage selon la revendication 6, comprenant une pointe d'électrode résistant à l'usure (22, 24) fixée à chacune de l'électrode centrale et de l'électrode de masse.
  8. Bougie d'allumage selon la revendication 6, dans laquelle la pointe de la bougie d'allumage comprend un métal noble.
  9. Bougie d'allumage selon la revendication 8, dans laquelle la pointe de la bougie d'allumage comprend un métal choisi dans le groupe constitué du platine, de l'iridium et de leurs alliages.
  10. Bougie d'allumage selon la revendication 5, dans laquelle le premier métal de l'électrode centrale comprend du cuivre.
  11. Culot métallique (12) pour bougie d'allumage, comprenant un corps de culot qui est un culot creux, le corps de culot comprenant une partie de base sensiblement cylindrique (14) ayant une surface inférieure (15) et
    une électrode de masse (16) fixée à la surface inférieure de la partie de base du corps de culot, l'électrode de masse comprenant une âme centrale (17) formée d'un premier métal thermoconducteur et d'une gaine externe (19) entourant l'âme, la gaine étant formée d'un deuxième métal comprenant du nickel, caractérisé en ce que la surface inférieure de la partie de base présente un évidement (23) et en ce que l'électrode de masse est fixée à la surface inférieure de la partie de base dans son évidement.
  12. Culot de bougie d'allumage selon la revendication 10, dans lequel l'évidement de la surface inférieure comprend une rainure annulaire (25) qui s'étend autour d'elle.
  13. Culot de bougie d'allumage selon la revendication 12, dans lequel la rainure annulaire s'étend de manière sensiblement continue autour de la surface inférieure.
  14. Procédé de fabrication d'une bougie d'allumage, comprenant les étapes suivantes :
    a) on met en oeuvre un culot métallique (12) avec une partie de base cylindrique (14) ayant une surface inférieure (15) dans laquelle est formé un évidement (23);
    b) on met en oeuvre une électrode de masse (16) ayant une âme centrale (17) formée d'un métal thermoconducteur et une gaine externe (19) entourant l'âme, le métal dont est formé l'âme ayant une conductibilité thermique supérieure à celle de la gaine environnante;
    c) on place une extrémité de l'électrode de masse adjacente à la surface inférieure du culot et alignée avec son évidement, de sorte qu'une partie de l'extrémité de pointe (27) de l'électrode de masse pénètre dans l'évidement; et
    d) on soude l'électrode de masse sur le culot.
  15. Procédé selon la revendication 14, dans lequel l'extrémité de pointe de l'électrode de masse forme sensiblement une section de diamètre réduit qui s'ajuste dans l'évidement du culot.
  16. Procédé selon la revendication 14, dans lequel l'évidement se présente sous la forme d'une rainure annulaire (25) s'étendant autour de la surface inférieure du culot.
  17. Procédé selon la revendication 16, dans lequel la rainure annulaire s'étend de manière sensiblement continue autour de la surface inférieure du culot.
EP00941440A 1999-06-16 2000-06-15 Culot de bougie d'allumage comportant une electrode de masse bimetallique, bougie d'allumage equipee dudit culot et procede de fabrication associe Expired - Lifetime EP1183762B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US09/334,533 US6326719B1 (en) 1999-06-16 1999-06-16 Spark plug shell having a bimetallic ground electrode spark plug incorporating the shell, and method of making same
US334533 1999-06-16
PCT/US2000/016478 WO2000077901A1 (fr) 1999-06-16 2000-06-15 Culot de bougie d'allumage comportant une electrode de masse bimetallique, bougie d'allumage equipee dudit culot et procede de fabrication associe

Publications (2)

Publication Number Publication Date
EP1183762A1 EP1183762A1 (fr) 2002-03-06
EP1183762B1 true EP1183762B1 (fr) 2006-03-01

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EP00941440A Expired - Lifetime EP1183762B1 (fr) 1999-06-16 2000-06-15 Culot de bougie d'allumage comportant une electrode de masse bimetallique, bougie d'allumage equipee dudit culot et procede de fabrication associe

Country Status (7)

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US (2) US6326719B1 (fr)
EP (1) EP1183762B1 (fr)
AT (1) ATE319207T1 (fr)
CA (1) CA2376980C (fr)
DE (1) DE60026304T2 (fr)
MX (1) MXPA01012850A (fr)
WO (1) WO2000077901A1 (fr)

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Publication number Publication date
CA2376980A1 (fr) 2000-12-21
ATE319207T1 (de) 2006-03-15
MXPA01012850A (es) 2002-11-07
US20020011768A1 (en) 2002-01-31
EP1183762A1 (fr) 2002-03-06
US6326719B1 (en) 2001-12-04
CA2376980C (fr) 2009-02-10
DE60026304D1 (de) 2006-04-27
WO2000077901A1 (fr) 2000-12-21
DE60026304T2 (de) 2006-11-02
US6406345B2 (en) 2002-06-18

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